Engine: D5: Heavy black smoke on acceleration - P0244

[Yamaha4Ever]

Hello all! I'm new to this forum and already finding it to be a valuable resource in diagnosing my motoring woes.

I recently purchased a 2002 s60 d5 with ~150k miles that needs a bit of tlc. My current issue is that under acceleration I get a very thick cloud of black smoke out the exhaust. Harder acceleration makes a thicker could until full throttle where I almost can't see the car behind me. While it's great for stopping tailgators I'd rather not drive around billowing soot everywhere I go!

I also have a p0244 dtc (waste gate regulating valve A performance problem). As I understand these cars don't use a waste gate but instead use the vnt system to limit boost??? Someone correct me if I'm wrong. My peak boost seems to be around 32-34psi (map sensor reading).

So far I've tried:
- Replacing the turbo control valve (above starter motor) with a £20 ebay replacement, had no effect
- Block vaccum line going into the valve on the airbox that leads to the engine mounts with a small bolt (to take the vac mounts out of the equation) also had no effect
- Checked operation of the vnt ring by sucking on the line going to it, I could hear something moving when I did and it seemed to hold the vaccum so I assume it's OK

I also noticed inside the charge pipe leading into the inlet manifold there was a lot of soot, but I think that's an effect of the smoke rather than a cause.

Since the car came with this issue I can't say when it started or compare with how it drove before, but it seems to drive OK. If it weren't for the mirrors I wouldn't know there was a problem!

[Simmy]

check the intercooler for splits holes and bowing . clean out and check the egr valve is working and do a leakback test on the injectors its also possible the car has a tuning box fitted or a poor remap.

[wynnj]

Also, check for splits/holes in the pipes to the intercooler.

[Yamaha4Ever]

That's a good idea about a leak off test, I'll have a look around the boost pipes and do the test sometime tomorrow and post what I find 👍

[davebb]

you will not have HIGH BOOST reading with any leaks in intercooler or boost pipes,But the black smoke could well be a bad intercooler or split boost pipes, so you will see lower boost psi,
Yes this boost reading should be 16-17 psi over atmospheric pressure that is 14.7 psi,
Dave

[Yamaha4Ever]

You were right on the money there with the split intercooler theory by the looks of it. I had a look at the boost pipes today and found the bottom of my intercooler completely soaked in oil and bowed downwards. I had a friend rev the engine a little and I could feel the air leaking out with my hand.

New intercooler has been ordered so will update in a couple of days with the results 👍

[Simmy]

make sure to order the right one i believe there are 2 types.

[davebb]

yes you are correct, the 2002 needs a intercooler without MAP sensor hole/fitting
Dave